I then proceeded to take the damn air con compressor "clutch" off - this is a pig as there isn't any info available.

I believe the compressor to be a Denso 6seu16c but with a strange clucth mech. Unlike older units the bit at the end which looks like a bolt is not a bolt and the pulley is fragile plastic! Anyway, put the original bet back on then jamn the pulley with a bit of wood, insert some 90 degree pliers into the hole and then you can spin off the cover plate in an anti-clockwise direction. This leaves the clutch and pulley etc in place still and so I believe you then need to get some strong thread locking compound and then put the plate back on, let the compound set and then redo the above, this time taking the clutch with you. Unfortunately I didn't know this and so I hacked mine as you can see! The pulley pulls of easily after that and the rubber "cushions" too. Mine looked in good shape and so I was a bit bemused as to why the metal on metal noise was happening. On the compressor there was a bit of movement, but not much so the tolerance must be tiny.

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Update: couldn't remove pulley in situ or even when I took the compressor off the car! Bought a new compressor in the end after cutting my hands twice! Ridiculous - all because of worn rubber bits that can't be replaced.

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